Spiral carding apparatus

ABSTRACT

This invention relates to the carding of textile fibers and is directed particularly to tapering the worker roll in spiral carding machines, thus providing a means for eliminating fiber damage.

United States Patent 1 91 Brown et al. I Jan. 7, 1975 SPIRAL CARDING APPARATUS [75] Inventors: Roger S. Brown, New Orleans; [56] References C'ted Philip L. Rhodes, Chalmette, both N T D STATES PATENTS f L 3,685,100 8/1972 Brown et al. 19/98 [73] Assignee: The United States of America as represented by the Secretary of Primary Exammerl )orsey Newton Agriculture Washington D C Attorney, Agent, or FzrmM. Howard S1lverste1n; Max

D. Hensley [22] Filed: Oct. 26, 1973 21 Appl. No.: 410,150 1 ABSTRACT This invention relates to the carding of textile fibers 52] U S a 19/99 19/105 and is directed particularly to tapering theworker roll [51] g 15/20 in spiral carding machines, thus providing a means for [58] Field of Search 19/90, 97, 9s, 99, 105, fiber damage- 3 Claims, 6 Drawing Figures Patented Jan. 7, 1975 4 Sheets-Sheet l Patented Jan. 7, 1975 3,858,277

4 Sheets-Sheet 5 Patented Jan. 7, 1975 4 Sheets-Sheet 4 FIGS SPIRAL CARDING APPARATUS FIELD TO WHICH THIS INVENTION RELATES This invention discloses a method for eliminating fiber damage in spiral carding machines.

More specifically, the invention discloses a method of varying the setting between the carding cylinder and the worker roll in spiral carding machines.

The conventional spiral carding machine, US. Pat. No. 3,685,100, used for the purpose of separating partially opened fibrous material into individual fibers comprises a cylinder of uniform diameter which has a multiplicity of teeth projecting from its surface. Set in close and uniform proximity to the cylinder is a worker roll of uniform diameter, which also has a multiplicity of teeth projecting from its surface. The partially opened fibrous material is introduced at one end of the two roll system and follows a spiral path to the opposite end of the system where the individual fibers are discharged. With this arrangement, the setting between the carding cylinder and the, worker roll is uniform from end to end, and in practice this setting is approximately 0.010 inches, which is required for obtaining individual fibers at the discharge end of the system. This setting is too close for the introduction of relatively large tufts of tangled fibers and results in the fibers being damaged in the initial carding stages.

The principal objective of this invention is to provide a means for eliminating fiber damage in a spiral carding machine which is capable of continuously separating partially opened fibrous material into individual fibers.

Other objectives of the invention and the mannerin which they are accomplished are discussed in greater detail in the following description and drawings illustrating a machine embodying the principles of the invention.

In particular, this invention consists of a spiral card having a card cylinder, a worker roll, a feeding means, a means for causing the fibers to follow a spiral path along the length of the carding cylinder, and a means for fiber removal. The'worker roll is so constructed that with its axis parallel to the axis of the carding cylinder, the space between the surface of the carding cylinder and the surface of the worker roll, decreases from the entrance end to the discharge end. The varying setting between the carding cylinder and the worker roll allows an open setting for the initial carding cycles and a progressively closer setting for the final carding cycles.

The invention is adapted to be used in the carding of various types of fibers, but is disclosed particularly in relation to the carding of cotton fibers.

In order that the invention may be fully understood, reference is made to the description which follows and to the accompanying drawings in which:

FIG. 1 is a side elevation of a complete apparatus assembly and as such, shows the relative positions of the fiber carding component, the fiber feeding and worker roll component which is the subject of this invention, the associated support members, and the driving means for a complete apparatus.

FIG. 2 is an exploded view of the carding apparatus showing the latter with the end cover plates removed, but with the cover in place.

FIG. 3 is an elevation, in perspective, of the cover of the carding apparatus, showing the disposition of the channels.

FIG. 4 is a cross section of the cover, taken on line 44 on Flg. 3, showing a portion of the channels and details of the exit port for the fibers.

FIG. 5 illustrates an improved embodiment of the worker roll.

FIG. 6 illustrates another improved embodiment of the worker roll.

Referring now to FIGS. 1 and 2, l is the main base for the assembled apparatus. Support 101 is secured to the main base and supports carding cylinder 11 by means of the journaled ends of the carding cylinder shaft 12. Support 102 is likewise secured to the main base and positions the worker roll 14 by means of the journaled ends of the worker roll shaft 15.

The axial ends of the fiber carding component 2, which component comprises carding cylinder 11 and carding cylinder covers 19 and 20, are closed with end plates 28 and 29 secured by machine screws 3 and 4. Fiber carding component 2 is secured by machine screws, not shown, to base 1.

The carding cylinder is driven by electric motor 6 via motor pulley 7, belt 8, and carding cylinder shaft pulley 9, which pulley is secured to carding cylinder shaft 12.

Slot 10 is an opening that provides communication between the inside of the carding cylinder lower cover and the outside. The slot extends transverse the fiber carding component, axially parallel to the carding cylinder and provides an outlet for the trash as it is removed from the fibers during the carding operation.

Worker roll 14 is driven by electric motor 106 via motor pulley 107, belt 108, and worker roll shaft pulley 109, which pulley is secured to worker roll shaft 15. Partly opened fiber in the form of a narrow lap 201 (i.e., from a fiber condenser) enters the apparatus via the worker roll and feed plate 17. Opened fiber 202 exits the fiber carding component.

In the apparatus as illustrated in FIG. 2, the carding cylinder comprises a metal drum 11 that may be any size and length but is preferably 2 inches to 6 inches in diameter and 2 inches to 6 inches long. The cylinder is provided with an axle 12 which is journaled in suitable bearings not shown, in a conventional manner. The cylinder is driven by a suitable power source as shown in FIG. 1. The peripheral surface of carding cylinder 11 is surfaced with any one of the various surfaces that are commonly used for carding purposes, such as metallic card clothing 13.

A worker roll 14 is positioned adjacent to the periphcry of carding cylinder 11, its axis parallel to axis of carding cylinder 11 and is provided with an axle 15, also journaled in suitable bearings, not shown, in a conventional manner. The worker roll 14 may be covered or surfaced with any material which will offer resistance to the fiber tufts being carried by the clothing 13 of the carding cylinder 11. For efficient performance we prefer to use a surface wound metallic wire 16 having approximately 16 points per inch. The worker roll 14 may be the same size as the carding cylinder 11.

A narrow width feed plate 17 is positioned at one end of and adjacent to the worker roll 14, with its nose 18 in close proximity to the periphery of carding cylinder 11.

The lower portion of the carding cylinder 11 is enclosed with a close fitting cover 19 in which any suitable opening such as 10 shown in Flg. l is provided to permit trash removal. The cover 19 may be of any desired configuration such as perforated metal or grid bars, which prevents the escape of fibers from the periphery of the carding cylinder 11. Also, the surface of the cover 19 adjacent to the periphery of the carding cylinder 11 may be covered or surfaced with any material which will offer resistance to the fiber tufts being carried by the clothing 13 on the carding cylinder 11. For efficient performance we prefer surface 19 to be smooth and continuous except for one small opening such as shown in FIG. 1 for trash removal.

- The upper portion of the carding cylinder 11 is enclosed by a specially constructed cover 20, the details of which are shown in FIGS. 3 and 4. The cover 20 has a contoured inner surface 21 which is contoured to essentially the same radius as the carding cylinder 11. The contoured surface 21 contains a plurality of individual channels 22, 23, 24, 25, and 26 positioned at an angle to the axis of the carding cylinder 11. Channels 22, 23, 24, 25, and 26 commence at a point on contoured surface 21 and traverse any portion of the cirumference of carding cylinder 11, preferably one third of the circumference. Said channels 22, 23, 24, 25, and 26 end at an axially advanced point on surface 21. The discharge of the first channel 22 is circumferentially aligned with the entrance of the second channel 23; the discharge of the second channel 23 is circumferentially aligned with the entrance of the third channel 24, and so on for the remainder of the channels 25 and 26. A discharge aperture 27 is located in the cover 20 near the end diagonally opposed to the position of the feed plate 17. The angle of the channels 22, 23, 24, 25, and 26 causes the fibers to follow a spiral type path from the feed plate 17 at one end of the carding cylinder 11 to the discharge aperture 27, in the cover 20 at the other end of the carding cylinder 11. End plates 28 and 29 are provided for sealing each end of the assembly. The feed plate 17 upper and lower covers 19 and 20 and end plates 28 and 29 are secured in their respective locations, as shown in FIGS. 1 and 2 by machine screws (not shown).

In operation, a continuous supply of partially opened fibers in the form of a narrow strip 201 (i.e., from a fiber condenser machine) is provided to the feed plate 17 where the fibers are engaged by the surface 16 of the worker roll 14. The worker roll 14 performs as a feed roll in conjunction with the feed plate 17 and its speed is governed (a) by the carding capacity of the carding component, and (b) by the through put rate at which it is desired to operate the machine. The fibers are carried forward to the point where they are engaged by the metallic card clothing 13 on the carding cylinder 11 which is operated with a surface speed sufficiently high to impart a centrifugal force to the fibers so as to project said fibers away from the carding cylinder 11, Le, approximately 5,000 rpm. for a 3-inch diameter cylinder. Due to the high surface speed of the carding cylinder 11, all fibers are combed or carried away from the surface 16 of the worker roll 14 and carried under the specially constructed cover 20 where they encounter the initial channel 22. The centrifugal force acting on the fibers causes them to leave the clothing 13 of the carding cylinder 11 and follow the channel 22 along the carding cylinder 11. Leaving the channel 22, the fibers are re-engaged by the clothing 13 and are carried past the lower cover 19 where foreign matter is ejected through a cleaning slot 10 shown in FIG. 1. The fibers are then carried by the clothing 13 past the worker roll 14, where they are intensely carded by the interaction of the carding clothing 13, and surface 16 of worker roll 14. The carding action is greatly intensified at this point due to the fibers being projected by centrifugal force into the carding area bounded by the surfaces of the carding cylinder 11 and worker roll 14. All fibers are again removed from the surface 16 of the worker roll 14 by the clothing 13 of carding cylinder 11, and carried under the upper cover 20 to enter the second channel 23, and subsequently the advancing, cleaning, carding cycle is repeated. The number of cycles is determined by the number of channels 22, 23, 24, 25, and'26 in upper cover 20 which may be any number desired.

FIG. 5 schematically illustrates an improved design of the worker roll 114. The worker roll 114 is uniformly axially tapered from one end 117 to the other 118, and its peripheral surface 116 is clothed as previously described. The worker roll 114 is positioned in the normal manner with its axis parallel to the axis of the carding cylinder and the small end 118 next to the feed plate. The axial taper of the worker roll 114 provides a varying setting between the worker roll 114 and the carding cylinder 11 which is greater for the uncarded fibers being fed and progressively decreases as the fibers traverse the length of the worker roll 114 and the carding is completed. With this arrangement, the forces on the tangled fibers being fed are reduced by the wide setting at the small end 118 of the worker roll 114, and fiber damage is eliminated. As the fibers traverse the length of the worker roll 114, the size of the tangles is reduced in proportion to the taper of the worker roll 114, resulting in more or less uniform forces acting on the fibers as they traverse through the system. In practice, it was found that a worker roll 114 having the small end 118 0.080 inches less than the large end 117 provided the required taper for eliminating cotton fiber damage.

FIG. 6 schematically illustrates another improved design of the worker roll 214. The worker roll 214 is constructed with half the length 217 of the worker roll 214 having a slightly largerdiameter than the other half 218. Both halves 217 and 218 have their peripheral surfaces 216 clothed as previously described. The worker roll 214 is positioned in the normal manner with its axis parallel to the axis of the carding cylinder 11 and the small end 218 next to the feed plate 17. With this arrangement an open setting is provided between the first half2l8 of the worker roll 214 and the carding cylinder for processing the tangled fibers being fed and between the second half 217 of the worker roll 214 and the carding cylinder, there is a close setting which is required for complete fiber separation.

We claim:

1. In a spiral carding machine comprising a. a support member;

b. a carding cylinder rotatably mounted on said support member;

means for feeding partially opened fibers to said cardingcylinder comprising a worker roll and a narrow feed plate located at one end of both said cylinder and said roll, said feed plate tangentially adjacent to the worker roll and with its nose in close proximity to the periphery of said carding cylinder, said worker roll and carding cylinder having parallel axes; d. a cover enclosing said carding cylinder and having a plurality of channels on the inner surface thereof positioned at an angle to the axis of said carding 6 cylinder and capable of coacting with said cylinder thereof adjacent to said feed plate. to Cause Sald fibers to follow a Spiral P from the 2. The improvement of claim 1 wherein said roll is feed plate at one end of the carding cylinder to a uniformly tapered discharge aperture in the cover ad acent to the other end of said carding Cylinder; 3. The improvement of claim 1 wherein said roll the improvement wherein; tapered in a series of discrete steps. said worker roll tapers axially, with the small end 

1. In a spiral carding machine comprising a. a support member; b. a carding cylinder rotatably mounted on said support member; c. means for feeding partially opened fibers to said carding cylinder comprising a worker roll and a narrow feed plate located at one end of both said cylinder and said roll, said feed plate tangentially adjacent to the worker roll and with its nose in close proximity to the periphery of said carding cylinder, said worker roll and carding cylinder having parallel axes; d. a cover enclosing said carding cylinder and having a plurality of channels on the inner surface thereof positioned at an angle to the axis of said carding cylinder and capable of coacting with said cylinder to cause said fibers to follow a spiral path from the feed plate at one end of the carding cylinder to a discharge aperture in the cover adjacent to the other end of said carding cylinder; the improvement wherein: said worker roll tapers axially, with the small end thereof adjacent to said feed plate.
 2. The improvement of claim 1 wherein said roll is uniformly tapered.
 3. The improvement of claim 1 wherein said roll is tapered in a series of discrete steps. 